Knockdown Spool with Integrally Recessed Hexagonal Drive Connection

ABSTRACT

A knockdown spool comprising a one piece barrel and having a pair of end flanges releasably attached through rotational motion to opposite ends of the barrel by locking means capable of being released in order to separate end flanges from barrel. The barrel contains aligning and locking channels which cooperate with a protrusion on outside walls of flange hub. The aligning and locking channels contain a curve and cusp serving as locking mechanism. Integrally designed within the hub is a recessed passage way leading to a recessed multi-faceted drive connection. Said drive connection of the spool provides a user the opportunity to thereby create a powered mechanical device for quickly and conveniently winding, re-winding, dispensing and storing of or re-using materials of long continuous lengths by attaching the spool to a powered driver via a multi-faceted bit.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims benefit of prior filed co-pending provisional application No. 61/209,278 entitled “Knockdown Spool with Integrally Recessed Hexagonal Drive Connection” filed on Mar. 5, 2009 in the name of Cory Arthur Strong, said provisional application being hereby incorporated by reference as if fully set forth herein.

BACKGROUND OF THE INVENTION

This invention pertains to so called knockdown reels of the type which, at present, comprise cylindrical or tubular barrels of predetermined length having flanges on opposite ends thereof containing a hub with engage-able connection points formed in various ways which are connected to opposite ends of the barrel at the time the reels are to be used. Reels of this type are shipped to manufactures, and distributors in knocked down condition for purposes of compactness during the shipping process. They are consumed in large quantities by manufactures and users of strand material such as electric wiring, string, rope, chain, and other materials and objects in long continuous lengths from light weight to heavy weight. Reels of this type quite commonly are formed at present from certain synthetic resin compounds or plastics while others are formed from sheet metal, cardboard, or wood, in various ways. In general, the present invention pertains to reels of a less heavy construction. These heretofore mentioned aspects of the current spool art are of benefit and interest to the spool manufacturers and distributors. However, they lack appeal and functionality for end consumers in trades, households, and light industrial applications.

The manufacturer or distributor who purchases the spool from the spool manufacturer, most often an industrial or commercial manufacturer or distributor, winds or wraps goods on the spool by way of mechanical means. The most often used method is a permanently mounted, industrial bench winding device. The manufacturer or distributor then dispenses the material as needed or sells the spool with the material on it as a consumer good to distributors or retailers. The end consumer who purchases either the entire spool of goods or a portion of the goods dispensed from the spool receives no benefit nor has interest in the spool and, as a result, either discards the spool, or in the case of heavy industrial type spools, return ships it. If the end user or consumer has the need or desire to re-wind or store the dispensed material for re-use, the current spool art offers no way to accomplish this quickly and conveniently without the use of an industrial bench winder. An exception is a reel design specific to the flying of kites, not of the knock down type, discussed later. Consumers or end users, specifically households and light industry, have long sought a means to quickly and conveniently re-wind, dispense, re-use and/or store light weight goods on spools in the interest of conservation and cost saving. Without having access to a permanently mounted, expensive, and cumbersome industrial type bench winding device, and the ability to operate it, the heretofore mentioned tasks are impractical, if not impossible, as well as time consuming.

Prior patented art found in the United States Patent Office includes, U.S. Pat. No. 6,045,087, Vislocky, et al. Apr. 4, 2000, and U.S. Pat. No. 5,575,437, Campbell, Nov. 19, 1996 that pertain to knockdown spool assembly and disassembly, specifically the ease thereof. The art in both cases consists of improvements to overall strength and alignment of the barrel to fit into the flange for rapid assembly by the user, and in the case of Campbell, rapid disassembly. U.S. patents McCaffrey, U.S. Pat. No. 4,903,913, February 1990, and Crellin, U.S. Pat. No. 3,785,584, January 1974 both address knockdown spools, however, in a different way. The art from these patents attempts to address the problems of loose fit, lack of positive interlocking means to attach the barrel to the flanges, and overall strength of an assembled spool. Additionally, these four mentioned sources of prior art focus on a form of snap together parts as an improvement or alternative to spin welding, glue, or solvents as the attachment method in the interest of conserving space for shipping purposes. This art provides adequate solutions to the aforementioned issues but is different from this invention in several ways. None of this prior art mentions, depicts, or includes as integral to the design, an invention that permits a user to mechanically re-wind or dispense for future use, material or objects in long continuous lengths quickly and conveniently, without the use of an industrial bench winding device. This invention makes these tasks possible with the attachment of a common, hand-held, powered driver.

Current spool manufacturing methods provide viable products for the spool manufacturers, manufacturers of goods that need to be placed on spools, and finally distributors. They address the need to ship large quantities of spools in relatively small packages in addition to quick assembly and in some cases disassembly. They are also designed to be used in conjunction with the heretofore bench winding method. The bench winder is a widely accepted and commonly used method of winding material onto a spool in an industrial setting. However, these spool manufacturing methods do not provide a quick and convenient way to re-wind or dispense for future use material or objects in long continuous lengths for the end consumer in a household, trade, or light industrial environment or application. Many objects or materials in long continuous lengths can and do have more than one use or can be re-used many times. Instead, they are often discarded or thrown away due to lack of the ability to quickly and conveniently re-wind or dispense material.

Fagan, in U.S. Pat. No. 5,190,237 shows a reel or spool driven by a powered driver to wind kite string. As indicated in the title of the art, this reel includes a clutch mechanism, which inherently comprises several moving and stationary parts to accomplish the job. Additionally, this design requires a specific order of assembly. The clutch assembly and it's many parts of the Fagan design are eliminated with this invention, which includes an integrally designed hexagonal drive connection not requiring assembly. Thornbury, U.S. Pat. No. 5,277,350, teaches of a design incorporating a powered driver using an adapter(s) to connect to one of the kite reel handles. Like Fagan, Thornbury provides a method for rapidly winding kite string on a reel or spool using additional parts or adapters. Finally, Peterpaul, U.S. Pat. No. 6,550,712, adapts a spool to a powered driver using hub and sleeve adapters thereby creating a way to wind material onto a spool. These examples are for a single, specific, recreational activity use and employ several pieces, parts and/or adapters requiring assembly before a powered driver can be attached. The recessed integral hexagonal drive connection in this design effectively eliminates the additional pieces and creates the opportunity for a portable, hand-held, powered, winding and storage spool device. The methods mentioned above, although valid winding devices, are cumbersome when compared to the compact recessed integral design provided with this invention. Additionally, those patents are not of the knockdown spool category. This invention reveals a knockdown spool providing the opportunity for use as a portable winding or storage device when attached to a common hand held powered driver.

It is determined that in a review of the prior art that there is no knockdown spool design incorporating a recessed integral hexagonal drive connection design which permits a user to quickly and conveniently attach a powered driver to a spool thereby creating a portable winding and storage spool device for re-winding, dispensing, or storing objects or materials in long continuous lengths in a household, trade, or industrial environment or application.

BRIEF SUMMARY OF THE INVENTION

The invention, an improved knockdown spool, has a recessed integral hexagonal drive connection. The drive connection is integrally designed into the flange hub, reinforced for strength and recessed for ease of use. It is an object of this invention to create a device which allows a user to rapidly connect a common, hand-held, powered driver to the spool for quick, convenient re-winding, dispensing, re-using and or storing objects or materials of long continuous lengths.

Additionally, another object of this invention is to create a device for the said purposes which is easier on the user to hold and manipulate. The aforementioned recessed design of the hexagonal drive connection provides the benefit of reducing the moment arm and top heavy feel by allowing the user to operate with a hand as close to the spool as possible after the driver is attached.

It is a further object of this invention to create a device which is used for the retrieval and storage of continuous lengths of materials or objects. The storage of the devices are aided by a unique design to facilitate stacking of the devices.

It is also an object of this invention is to create a device that is economically positioned in the marketplace, where people will buy multiple sets of the device and use as a permanent storage device, yet enable the user to “knock-down” the device easily when not in use.

It is a further object of this invention to have a multi-stage drive mechanism acceptance portal, whereby a plurality of power driven mechanisms can be adapted to function within this one device.

It is a further object of this invention to create an economically viable product that one uses to store wound materials for long period of time, rather than having expensive collapsible spools that are too expensive to store material on them.

Accordingly, the invention provides an improved knockdown spool for household, trade, or industrial use, to provide an economical, convenient device to re-wind, dispense and re-use objects or materials of long continuous lengths, and to encourage conservation of these materials by providing the heretofore mentioned benefits. Still further objects and advantages will become apparent from a study of the following description.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

In FIG. 1 is a side elevation of a single flange

In FIG. 2 is a frontal elevation of the exterior face of the flange

In FIG. 3 is a cross-sectional view along cutting line A-A of FIG. 2, detailing the interior face and hub of the flange.

In FIG. 4 is a detail of the exterior end of the hub detailing the winding means interface.

In FIG. 5, a detail view of the exterior of flange in FIG. 2 detailing the ingress portal to the winding means interface.

In FIG. 6, the interior side of the flange is shown in an oblique view detailing the exterior of the hub along with the securement means and sear catch.

In FIG. 7, the barrel is view from a frontal elevation.

In FIG. 8, a chord section, shown as C-C on FIG. 7, is taken from the frontal elevation in FIG. 7 detailing the interior of the barrel.

In FIG. 9, an oblique elevation of the exterior of the barrel enabling the viewing both ends of the barrel.

In FIG. 10, a completed assembled unit is shown in an oblique elevation.

In FIG. 11, the completed assembled unit is shown through a longitudinal cross-section.

In FIG. 12, an assembled unit is shown from a top elevation detailing the engagement of the securement means.

In FIG. 13, as assembled unit is shown from a side elevation detailing the sear catches and their relation to the securement means.

DETAILED DESCRIPTION OF THE INVENTION

The present invention will be detailed in relation to the aforementioned drawings. All disclosure is representative of the best mode of practicing this invention but that it is assumed that those skilled in the art will be able to practice this invention in other fields of application, nor does this disclosure limit the construction of this invention to the parts herein disclosed. Applicant recognizes that development of future inventions may lead to better parts than those disclosed, but the intent of this application is to show the best available parts currently available by their fit, form and function to their exclusive use by this application.

The device consists of two primary parts, one of which flange 36 is used in a pair, which are able to be used on either end of barrel 2. The uniqueness of this design is that the user need not determine a left or a right flange of the spool as both flanges are the exact same, allowing for an easier user interface with the device.

FIGS. 7-9 detail the barrel 2 of the device. Barrel 2 is a basically circular core having a consistent bore, having both open ends to configured to accept the securement means. Barrel 2 has an external surface 14 which is, in this disclosure of the best mode to practice this invention, circular in nature. This disclosure is not limited to only circular outer surfaces as other surfaces, such as hexagonal or decagonal, may be used to facilitate a better gripping means or would better facilitate the storage of the wound lengths stored on the spool. Barrel 2 has an interior bore 12 which interfaces with flange hub 52 through a close fit tolerance, and has barrel end face 24 which terminates barrel 2. The distance between each barrel face 24 is determined by the capacity required and the material to be wound upon the barrel.

Barrel 2 also contains securement means 3, ingress to which is located along a common axis along barrel 2, said ingress being through securement means ingress 16. Ingress 16 is an opening through which securement post 70 passes. Post 70, as seen in FIG. 3 and FIG. 6, passes into ingress 16 through taper 15, said taper serves to direct the post into the ingress aiding the user in finding ingress 16. Slot 19 leads from ingress 16 towards channel 28. The user supplying lateral motion directs post 70 through slot 19 until the travel terminates upon contact the channel wall 28W. Where the width of slot 19 allowed for some locating play between post 70 and the walls 17 of slot 19, channel 28 has a distance between the walls that contacts post 70 with a close sliding fit as defined by ANSI B4.1 where there is interference between the post and channel walls. A natural radius or curve 28C facilitates the transition into the more confining space of channel 28. The user will rotate barrel 2 in the direction that moves post 70 through channel 28 until post 70 rotates through expansion zone 20, whereby the distance between the slot walls in channel 28 increases slightly to become a transition fit where is little contact or interference. Post 70 then rotates and comes in contact with cusp 22, whereby the post is firmly captured. User repeats the assembly action on the other flanges onto the barrel to complete the assembly. The assembled device is seen in FIG. 11.

FIG. 6 is an oblique perspective of the rear one of the two flange 36 required for the invention showing centrally located hub 52. FIG. 3 is a cross-sectional view detail the interior side of flange 36 along with a crossection of hub 52 where the recessed integral hexagonal drive connection passage way access opening 32 is shown along with the recessed integral hexagonal drive connection 54.

Hub 52 protrudes from the rear of flange 36 and contains not only the drive interfaces, but the securement post 70 and stiffening ribs 58. The front or external side of flange 36 has a raised panel pattern 38, which emanates from the center of the flange to the circumference of flange 36. There are multiple spoke projections, where there are an equal number of pattern panels 38 as there are spaces between them. The purpose of pattern panel 38 is four-fold. Firstly, it is noted that flange 36 is not a solid piece, but rather has the pattern as spokes. The use of patterns 38 decrease the weight of the flange, reducing the torque or moment required to rotate the device, and provides for visual identification of the wound material or product should the devices be stacked. Secondly, the use of pattern panel 38 increase the strength and rigidity of the flange in comparison to a solid disk of the same thickness and dimension. Thirdly, pattern panel 38 is substantially triangularly shaped and it's surface is contoured so that they create an interlocking weave as one pattern will intermesh with an open space of another flange, enabling a more stable stacking configuration should multiple devices be stacked upon one another. Lastly, flange pattern 38 has an aesthetic consumer product appeal and contains contours that can facilitate labeling. Beveled edge 62 is internally located along the circumference of flange 36. Edge 62 acts as a guide for the level winding of material onto barrel 2.

Located on the exterior surface 53 of hub 52 is beginning sear catch 60 and securement post 70, which are located directly opposite of one another along the diameter of hub 52. Securement post 70 is shown in FIG. 6 to be circular or oval in shape, but can also be square in square as seen in the cross-sectional view in FIG. 3. Cusp 22 will have a matching contour to the shape of post 70 in order to accommodate a contact fit between said cusp and said post. The location of post 70 is such as that when the post is secured located into cusp 22, barrel end face 24 is in contact with hub stop 55 as the distal end of sear catch 60 and in contact with the distal ends of stiffening members 58. A plurality of stiffening members 58 are radially located along horizontal axis of hub 52, on the exterior surface 53, said members having an proximal end, which is in contact with the interior side flange 36, and a distal end which terminates into a vertical face.

Sear catch 60, shown in FIGS. 1,3 and 6 has the purpose of providing a place to fasten down the end of the material sought to be rewound upon the barrel of the device. In this application, catch 60 has a vertical and a horizontal component with a radiused intersection between the two components. Space is provided between catch 60 and the interior of flange 36 to assist the user in placing the material onto the catch. The style of catch 60 is not determinative upon this application and various styles can be adapted for particular materials that are to be rewound onto the device, such as creases for holding wire or loops to hold to beads. Directly opposite of the horizontal component of catch 60, along the surface of flange 36, is sear catch opening 40 which aids the user in the attached or removal of the end of the material to be wound onto catch 60

Hub 52 has a proximal end with a recessed integral drive connection passage way 32 accessed from the exterior of flange 36 and a distal end that is at the farthest point away from the interior side of flange 36. A hexagonal socket drive portion 54 is located interiorally from passage 32, said passageway 32 being larger in diameter than drive portion 54, as seen in FIG. 5. FIG. 4 is a cross-sectional view of hub 52 showing the passage way 32 and drive portion 54 in axial communication with one another. Hub 52 is strengthen and stabilized by a plurality of radial ribs 56 extending radially from the exterior 59 of drive portion 54 connecting to the interior wall of hub 53. In this disclosure, the passage way opening 32 is circular in shape with a predetermined diameter made to accept a powered driver collet with hexagonal bit allowing the powered driver placement near flush to the exterior of flange 36 decreasing the moment arm and reducing the potential top heavy feel during use. In adapting to newer technologies, multi-sided collets are replacing knurled collects, and this device can be adapted to accept this new style of collets. It also allows for a hexagonal bit to be attached without a powered driver. There are a variety of type of combinations of collets and hex-shaped tools that will function within this device. The use of the wording hex or hexagonal is merely descriptive of the style of bits or shape of bits that can be adapted into this device. Other common styles of multi-faceted bits including Torx® and spline drive can be accommodated by simply configuring the drive portion 54 to accept other bit styles. As noted in the drawing Figures, the drive portion 54 is without any terminating stops, thus the length of the bit is not critical and can extend to or past the opposite hub for any purpose.

In operation a user takes the 2 flanges and the barrel of the knockdown spool and assembles them. Holding one flange in one hand and taking the barrel in the other hand, the user slides an open end face of the barrel over the hub wall, aligning the post on the hub wall with ingress in the barrel. Push the barrel over the hub until the post contacts the curve in the channel, then turn the barrel in the direction of the channel until it locks in place. Repeat these steps with the second flange. Accomplish steps in reverse to disassemble.

Once the knockdown spool is assembled it is now ready for use to wind, re-wind, dispense or store materials or objects of long continuous lengths quickly and conveniently. Hold the assembled spool in one hand. With the free hand, take a powered driver with a hexagonal bit of predetermined length and width and insert it into the recessed integral hexagonal drive connection opening until it stops or the driver contacts the flange disc. Now support the spool, as it is connected to the driver, by holding the driver with one hand. With the free hand, take the beginning of the material desired to be wound and attach it to the beginning sear catch by using a wide end or wrapping or bending the material. While operating the spool and driver combination in one hand, use the free hand as a guide for evenly winding the desired material on the spool. To dispense material operate same way using free hand to guide dispensed material. Material can be easily and neatly stored once on the spool or quickly and conveniently dispensed for re-use. This manner of use can be accomplished while sitting, standing or walking to dispense or wind material.

This device has succeeded in achieving the objectives of this invention, and though only current technology exists, future technologies may produce materials and components that would accomplish these objective in different or similar manners. These advances would be considered to be within the spirit, scope and intent of this patent and the claims herein disclosed 

1. A Knockdown Spool with Integral Recessed Hexagonal Drive Connection as herein disclosed, having a substantially tubular central member terminated by perpendicularly located patterned planar surfaces, further comprising; a first perpendicular planar flange, having an interior surface and an exterior surface, having a opening located in the geometric center of said flange, said interior surface terminating into the exterior surface through a sloping wall at the outer extents of said flange, said first flange containing a circular hub protruding perpendicular from said interior surface, said hub having an interior core and an exterior surface, axis of said hub being coincident with said geometic center axis, a second perpendicular planar flange, having an interior surface and an exterior surface, having a opening located in the geometric center of said flange, said interior surface terminating into the exterior surface through a sloping wall at the outer extents of said flange, said second flange containing a circular hub protruding perpendicular from said interior surface, said hub having an interior core and an exterior surface, axis of said hub being coincident with said geometic center axis, a hollow core, having a smooth inner circular bore and an outer circumferentially related shell, two external faces at opposite ends of said core, said inner circular bore being capable of physical connection with said first and said second flange, said core having securement means on said outer shell, and an engagement means securely conjoining said hub of said first flange to one end of said core and said hub of said second flange to opposite end of said core, said engagement means being rotationally biased, said conjoining process being rotationally reversible and where said engagement means being capable of multiple said rotational engagements.
 2. Knockdown Spool with Integral Recessed Hexagonal Drive Connection as disclosed in claim 1, where each of said hubs on said first flange and on said second flange possesses an external passageway and an internal socket, said passageway being in communication with said flange opening and is sized to accept a collet from a powered driver, and where said internal socket is in axial communication with said passageway and is configured to accept multiple faceted bits.
 3. A Knockdown Spool with Integral Recessed Hexagonal Drive Connection as disclosed in claim 2, where said internal socket does not have a terminating stop, and said internal socket of said first flange and said internal socket of said second flange are axially aligned.
 4. A Knockdown Spool with Integral Recessed Hexagonal Drive Connection as disclosed in claim 1, where said engagement means consists of a engagement post protruding from said exterior of said hub, and a channel cut from said external face of said core into the body of said core, said channel running for a distance along the longitudinal axis of said core then turning to be perpendicular to said longitudinal axis, said channel terminating in a cusp, said channel having a width closely conforming to the width of said post.
 5. A Knockdown Spool with Integral Recessed Hexagonal Drive Connection as disclosed in claim 4, where said post and said cusp are elliptical in shape.
 6. A Knockdown Spool with Integral Recessed Hexagonal Drive Connection as disclosed in claim 4, where said post and said cusp are polygonal in shape.
 7. A Knockdown Spool with Integral Recessed Hexagonal Drive Connection as disclosed in claim 1 where said hub has located thereupon a catch, said catch being diametrically opposed to said engagement post, said first flange and said second flange having an opening cut therethrough allowing access to said catch.
 8. A Knockdown Spool with Integral Recessed Hexagonal Drive Connection as disclosed in claim 1 where said exterior surface of said flange has a two or more panels emanating from said of said flange and terminating at the circumference of said flange, said panel having a contour that facilitates an interlocking interference when the exterior of one flange is place upon the exterior of another flange. 